METHOD OF COUPLING PLASTIC COMPONENTS TO METAL TUBING
A method of coupling tubular bodies is provided, particularly for use in fluid handling systems requiring a fluid-tight, pressurized joint. One tubular body is made from a polymer. The other tubular body is formed as a bare metallic body (e.g., aluminum tubing). The tubular bodies are positioned relative to one another (e.g., the metallic tubular body may be inserted within the polymeric tubular body). The tubular bodies are then joined together by generating heat (e.g., through induction welding) to cause heat transfer from the metallic tubular body to the polymeric tubular body thereby resulting in deformation of the polymeric tubular body and bonding of the polymeric tubular body to the metallic tubular body.
This application claims priority to pending U.S. Provisional Patent Application Ser. No. 60/722,108 filed on Sep. 30, 2005, the entire disclosure of which is incorporated herein by reference.
BACKGROUND OF THE INVENTION1. Field of the Invention
This invention relates to methods for coupling two or more components and, in particular, to a method for coupling polymeric components (including tubing) to metal tubing while providing a fluid tight, pressurized joint.
2. Discussion of Related Art
Motor vehicles may include various fluid handling systems, such as, but not limited to, fuel systems, power steering systems, heating and cooling systems, and hydraulic braking systems. These fluid handling systems may require the attachment of various tubular bodies, connectors and other components to create robust seals and fluid tight, pressurized joints for fluid handling.
A variety of methods are known for joining components of a fluid handling system. For example, ITT Industries, Inc. has previously developed a process under the trademark “POSIBOND” that utilizes spin welding to join two components. Spin welding does not, however, allow for the simultaneous creation of multiple joints and therefore requires an undesirable amount of time to create multiple joints. Spinwelding typically requires a bonding agent as well. Ashland, Inc. has previously developed a process under the registered trademark “EMABOND” using induction welding to joint two thermoplastic bodies. This process, however, requires the use of a bonding agent or resin disposed between the thermoplastic bodies and having metallic particles.
The inventors herein have recognized a need for a method for coupling components in a fluid handling system that will minimize and/or eliminate one or more of the above-identified deficiencies.
SUMMARY OF THE INVENTIONThe present invention relates to a method for coupling first and second components of a fluid handling system.
A method in accordance with the present invention includes the steps providing a first component, the first component comprising a tubular body having a bare metallic surface, and providing a second component, the second component made from a polymer. The method further includes the step of positioning one of the first and second components relative to the other of the first and second components. Finally the method includes the step of generating heat to deform the second component and bond the second component to the bare metallic surface of the first component.
A method in accordance with the present invention has significant advantages relative to conventional manufacturing methods for coupling fluid system components. The method allows two components to be joined together without the use of a bonding agent or other intermediary. The method also allows multiple, fluid tight joints to be formed simultaneously thereby reducing assembly time.
These and other advantages of this invention will become apparent to one skilled in the art from the following detailed description and the accompanying drawings illustrating features of this invention by way of example.
Referring now to the drawings wherein like reference numerals are used to identify identical components in the various views,
Component 12A may comprise flexible tubing for use in fluid handling. Component 12A is made from a polymer such as a plastic, and particularly a thermoplastic, and may be made of nylon. Component 12A may be cylindrical in shape may define a circular fluid passageway 16. Component 12A defines at least one opening 18 configured for insertion of component 14A. Component 12A may define multiple openings 18 (e.g, at opposite longitudinal ends of component 12A or at an intermediary point along component 12A) to allow interconnection of multiple components similar to component 14A. Component 12A may comprise monowall tubing as illustrated in
Referring again to
Referring again to
As mentioned hereinabove with reference to
The above described embodiments of fluid couplings have generally described and illustrated couplings in which a tubular polymeric component having a fluid passageway, such as component 12A, is bonded to a tubular component, such as component 14A, having a bare metallic surface at which a bond is formed between the components. Referring to
Referring now to
The inventive method may continue with the step 78 of positioning at least one of components 12A, 14A, relative to the other of components 12A, 14A. In accordance with one embodiment of the invention, step 78 may include the substep 80 of inserting component 14A into opening 18 of component 12A (see
Prior to forming the sealed joint between components 12A (or 12B or 12C or 12D or 66 or 68), 14A (or 14B or 14C), it may be desirable to apply a clamping load in the area of the joint to be formed. Accordingly, the inventive method may include the step 86 of applying a clamping load to the interface between components 12A (or 12B or 12C or 12D or 66 or 68), 14A (or 14B or 14C). The load may be applied using any of a variety of conventional tools and/or methods known in the art. The load may also be applied at multiple locations along components 12A (or 12B or 12C or 12D or 66 or 68), 14A (or 14B or 14C).
The inventive method continues with the step 88 of generating heat to deform the polymeric component 12A (or 12B or 12C or 12D or 66 or 68) and bond the polymeric component to the bare metallic surface of component 14A (or 14B or 14C). In a preferred embodiment, heat is generated by energizing a conductor proximate the tubular bodies 12A (or 12B or 12C or 12D or 66 or 68), 14A (or 14B or 14C). The conductor may, for example, comprise a coil through which current is fed from a power source. The inventive method thus employs a form of induction welding. The inventors herein have recognized that the resulting electromagnetic field providing inductive energy to the metallic component 14A will result in heat transfer to the polymeric component and, at sufficient levels, will result in deformation of the polymeric component through melting. This results in one or more bonds or joints or weld rings 90 between components 12A (or 12B or 12C or 12D or 66 or 68), 14A (or 14B or 14C) as shown in
The inventive method may be used to form a coupling between two components 12A (or 12B or 12C or 12D or 66 or 68), 14A (or 14B or 14C). In accordance with one aspect of the invention, however, the inventive method may be used to couple additional tubular bodies. Accordingly, the method may continue with the step 92 of positioning another component relative to two other components. For example, another component 14A or 14B may be inserted into an opposite end of any of components 12A, 12B, 12C, 12D. Alternatively, another component 12A or 12B may be inserted into an opposite end of tubular body 14A. The method may further continue with the step 94 of generating heat to deform the polymeric component and form another bond between the existing components and the added component. Where induction welding is used to generate heat, step 94 may include the substep of energizing one of (i) the conductor used in coupling the first two components and (ii) a second conductor, proximate the added component and the component to which it is being joined.
A method in accordance with the present invention has significant advantages relative to conventional manufacturing methods for coupling tubular bodies. The method allows two tubular bodies to be joined together without the use of a bonding agent or other intermediary. The method also allows multiple, fluid tight joints to be formed simultaneously thereby reducing assembly time. Further, the inventive method forms a strong, fluid tight joint that is capable of withstanding pressurized applications without the need for complex mechanical seals, while simultaneously reducing the cost and time of conventional manufacturing processes. It has even been determined that the inventive method described herein can be used to bond a plastic component such as component 12A, 12B, 12C, 12D, 66, 68 to the bare metallic surface of a component 14A, 14B, 14C despite the presence of oil or other lubricants. Accordingly, previous manufacturing steps requiring cleaning of components 14A, 14B, 14C to remove oil or other substances can be minimized.
Referring now to
Referring to
Referring to
While the invention has been shown and described with reference to one or more particular embodiments thereof, it will be understood by those of skill in the art that various changes and modifications can be made without departing from the spirit and scope of the invention.
Claims
1. A method of coupling first and second components of a fluid handling system, comprising the steps of:
- providing said first component, said first component comprising a tubular body having a bare metallic surface;
- providing said second component, said second component made from a polymer;
- positioning one of said first and second components relative to the other of said first and second components; and,
- generating heat to deform said second component and bond said second component to said bare metallic surface of said first component.
2. The method of claim 1 wherein said bare metallic surface comprises aluminum.
3. The method of claim 1 wherein said polymer comprises nylon.
4. The method of claim 1, further comprising the steps of:
- providing a third component, said third component comprising a tubular body having a bare metallic surface;
- positioning one of said second and third components relative to the other of said second and third components; and,
- generating heat to deform said second component and bond said second component to said bare metallic surface of said third component.
5. The method of claim 4 wherein said step of generating heat to deform said second component and bond said second component to said bare metallic surface of said first component and said step of generating heat to deform said second component and bond said second component to said bare metallic surface of said third component occur substantially simultaneously.
6. The method of claim 1, further comprising the steps of:
- providing a third component, said third component made from a polymer;
- positioning one of said first and third components relative to the other of said first and third components; and,
- generating heat to deform said third component and bond said third component to said bare metallic surface of said first component.
7. The method of claim 6 wherein said step of generating heat to deform said second component and said step of generating heat to deform said third component occur substantially simultaneously.
8. The method of claim 1 wherein said second component is directly bonded to said first component.
9. The method of claim 1 wherein said generating step includes the substep of energizing a conductor proximate said first and second components to generate heat transfer from said first component to said second component.
10. The method of claim 1 wherein said second component comprises an end cap.
11. The method of claim 1, further comprising the step of applying a clamping load to said first and second components.
12. The method of claim 1 wherein said positioning step includes the substep of inserting one of said first and second components within an opening in another of said first and second components.
13. The method of claim 12 wherein said one component has an end form formed on a first end of said one component.
14. The method of claim 1 wherein said positioning step includes the substep of inserting one end of one of said first and second components into a recess formed in one end of another of said first and second components between radially inner and outer surfaces of said another component, and said generating step bonds said another component to said one component on radially inner and outer surfaces of said one component.
15. The method of claim 1 further comprising the step of:
- providing a seal between said first component and said second component prior to said generating step.
16. The method of claim 1, further comprising the step of inserting a bonding agent between said first and second components prior to said generating step.
17. The method of claim 1, further comprising the step of repeating said generating step.
18. The method of claim 1, further comprising the step of providing a lubricant on said bare metallic surface of said first component prior to said generating step.
19. A method of assembling a fluid coupling, comprising the steps of:
- providing a first component, said first component comprising a metallic tubular body;
- providing a second component, said second component comprising a polymeric ring;
- positioning said second component around said first component;
- generating heat to bond said second component to said first component; and,
- providing a third component, said third component comprising a tubular body;
- inserting said first and second components into said third component until said third component securely engages said second component.
20. A method of packaging first and second components of a fluid handling system, comprising the steps of:
- providing said first and second components, said first and second components each comprising a tubular body defining a fluid passageway and formed as a laminate having an inner metallic layer and an outer polymeric layer;
- positioning one of said first and second components relative to the other of said first and second components; and,
- generating heat to deform said polymeric layers of said first and second components and bond said first and second components to one another.
Type: Application
Filed: Sep 27, 2006
Publication Date: Feb 7, 2008
Inventors: David C. Stieler (Lake Orion, MI), Dale L. Sleep (Hamilton, IN)
Application Number: 11/535,656
International Classification: B23P 11/02 (20060101); B21D 39/04 (20060101);